Carb issue!
 

Hi, i bought an 2003 arctic cat 400 4x4 non running.vi bought a carb rebuild kit and was rebuilding it today when i ran into an issue the float needle is smaller than the hole so i checked the old one and it was also smaller. Any ideas the carb is a keihin cvk 38fe sgj . i don't know if it's the original one or not but figured it was since it's oem and not Chinese.

Just to clarify...when you say float needle are you talking about the float bowl needle that rises as the bowl fills up and shuts off the fuel flow? If so...the needle (or plunger) is supposed to move up into the brass hole but then it rubber top (usually) plugs up the smaller hole inside...

Carb issue
 

Yes that's what I'm talking about the brass hole is way larger than the plunger or float valve it's crazy I've rebuilt plenty of carbs but i haven't ever ran into this issue any ideas why the brass hole i this carb is larger?

is there a smaller hole recessed into the brass piece that the float bowl needle is sealing against? Have you done a float needle seal check? When you turn on the fuel on and the bowl fills is it pissing fuel out of the overflow drain?

Carb issue
 

Yes it will not stay sealed it cocks the float valve to the side because the opening is too big.
https://cimg7.ibsrv.net/gimg/atvconn...e004722a71.jpg

https://cimg3.ibsrv.net/gimg/atvconn...b15ec660da.jpg

https://cimg1.ibsrv.net/gimg/atvconn...5e1803368d.jpg

Looks like you may be missing a piece that is supposed to go into there that the float needle is supposed to seal against. Check a parts breakdown print and take inventory.

Carb issue
 

Hmmm didn't think about that I'll check thanks